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3 5/8 sounds like a 1330 or 1350. The 1350 has larger diameter caps but same width.
1310 should be narrower than 3 5/8 but may have the same cap size as the 1330 or smaller. Considering you have caps that match I bet you have a 1310 to a 1330 issue.
You can order special u-joints that are combination sizes.
You can. They can be a real pain to get off, and to properly torque down. Also it can mess with the pinion preload. If your axle has a crush sleeve type system you can alter how the pinion mates with the ring gear inside the axle.
I am finding conflicting evidence on whether the D60 use a crush sleeve or shims. I will tell you this though, a 1/2 impact wrench is not going to get the nut tight enough. I had tried a few times with an impact wrench only to have the nut come lose and wondering what the sounds coming from my rear axle were. And you cannot just get a breaker bar and pipe on it to torque it down either as the drive system flexes enough your breaker bar and pipe will hit the ground before you can even torque it.
It seems crazy to me a D60 would have a 1310 yoke on it. What did it come out of?
You can. They can be a real pain to get off, and to properly torque down. Also it can mess with the pinion preload. If your axle has a crush sleeve type system you can alter how the pinion mates with the ring gear inside the axle
so it is do able but what can I do to prevent that
I couldn't tell you if it's a 1310 or whatever else but it is a lot narrower than than the u joint that is on it
Look at the dimensions on this conversion u-joint. I feel pretty confident you have a 1310 and 1330 issue. You could probably order the MOOG 253 ujoint locally and they would have it for you tomorrow if your local napa, advance auto, carquest, etc don't have one in stock.
The more I search around the internet it seems that later D60s have crush sleeves, but out of this era of truck it should only have shims. The issue then would be can you torque the nut down enough. I ended up using a 1" impact wrench from a relative to finally fix my problem. Final torque was unknown. A 1/2" impact wrench just cannot torque the nut enough because the internal workings of the axle give and flex, absorbing the energy to torque the nut.
I really do not know of an accurate way to torque down the pinion nut. I have tried several over the years with no avail other than the 1" impact wrench which likely applied more than the normal amount of torque.
I am finding conflicting evidence on whether the D60 use a crush sleeve or shims.
No Dana axle of any year or type has a crush sleeve.
Only the 9" has a crush sleeve (B7A-4662-A), 9's were only installed in F100/150 & Bronco.
The 1310/1330 "conversion" u-joint (2 cups are 1310's, two cups are 1330's) is Ford part number: C5TZ-4635-F .. The Spicer part number: 210392-X
1973/79 F250/350 Dana 60; 61-1 or Dana 70 (F350) rear axle depending on the application, could have 1310, 1330, 1310/1330 combination or 1350 u-joints.
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